Modern industrial wastewater treatment is no longer about a single piece of equipment. It is about how dozens of specialist technologies, sensors, pumps, tanks, aeration systems and control platforms come together to form a reliable, compliant and high-performance water treatment plant.
In this project, Aerofloat has delivered its largest ever biological treatment plant, integrating world class suppliers and advanced process control into a single, robust system designed to treat large volumes of industrial effluent with exceptional reliability.
Key Takeaways
The project:
Aerofloat’s largest ever biological treatment plant combines dozens of specialist technologies into a high-performance system for managing large volumes of industrial effluent.
Core biological processes:
Multiple biological treatment processes, including anoxic tanks, sequencing batch reactors (SBR) and aerated lagoons work together to ensure advanced nutrient removal, denitrification and pH adjustment.
Key Features
- DO and pH sensors, automatic probe cleaning, level instrumentation and flow meters feed a PLC, HMI, and Ignition SCADA system, allowing operators to fine-tune processes and monitor water quality and operations remotely.
- Surface and brush aerators, submersible mixers and roots blowers maintain oxygen levels and biological activity to drive efficient treatment and nutrient removal.
- All solids are captured and processed through a belt press, so no liquid waste leaves the site.
- All chemical systems include QR codes, SDS access and lockable enclosures, supporting safe and compliant operation.
- Final polishing through sand filtration ensures the final effluent meets strict discharge or reuse standards.
A treatment plant built for scale and reliability
This facility combines multiple biological treatment processes, including anoxic tanks, sequencing batch reactors (SBR) and aerated lagoons, allowing for advanced nutrient removal, including denitrification, ph adjustment in water treatment and biological oxidation.
The concrete tanks themselves were constructed by A1 Quality Tanks, using heavy-duty reinforced walls up to 350 mm thick. This ensures the structural integrity required for large-scale wastewater treatment systems operating 24 hours a day.
Precision monitoring and instrumentation
Accurate control is critical in biological systems. This plant uses:
- DO and pH sensors from Royce Water Technologies
- Automatic probe cleaning using compressed air
- IFM level instrumentation linked to floating pontoons
- Siemens flow meters for hydraulic balancing
These inputs feed directly into the PLC and SCADA system, allowing operators to fine-tune aeration, mixing and chemical dosing to keep the plant operating at peak efficiency.
Advanced automation and control
The entire plant is controlled by a large-scale Beckhoff PLC and HMI, built by Automation Engineers Australia and connected to Ignition SCADA software.
This provides:
- Live trending of water quality
- Process optimisation
- Alarm management
- Remote monitoring
This level of control is standard in high-end water purification technology companies delivering critical industrial wastewater management infrastructure.
Aeration, mixing and biological performance
The biological process relies on high-efficiency aeration and mixing equipment from multiple specialist suppliers:
- Surface aerators and brush aerators by Aeris Global
- Submersible mixers by Sulzer
- Roots blowers by Atlas Copco for final effluent aeration
Together, these systems maintain oxygen levels, biological activity and sludge suspension, driving efficient treatment and nutrient removal.
Sludge handling and zero liquid discharge
One of the most important outcomes of this system is that no liquid waste leaves the site.
All solids are captured and processed through a VFold belt press, producing dewatered sludge that is sent to landfill. This is a critical part of modern sludge dewatering solutions and helps facilities dramatically reduce transport and disposal costs.
Chemical handling and safety
The plant includes:
- Double-bunded caustic tanks
- Carbon source tanks
- Aerofloc P600 dosing systems
- ProMinent dosing skids
- Polymaster IBC bunding
All chemical systems include QR codes, SDS access and lockable enclosures, supporting safe and compliant operation.
Filtration and final discharge
Final polishing of treated water is achieved through sand filtration, using:
- Waterco filter vessels
- Bray and Burmad valves
- Ebara discharge pumps
This ensures the final effluent meets strict discharge or reuse requirements, whether it is sent to sewer, reuse or a recycling water plant.
A model for future industrial water treatment
This plant demonstrates what modern wastewater treatment plants, water treatment plant suppliers and industrial effluent treatment systems can achieve when engineering, automation and operations are fully integrated.
It is not just a waste treatment plant. It is a highly optimised industrial wastewater treatment solution designed for long term performance, regulatory compliance and environmental protection.
